WIP: 1:5 scale 3D printed Chain Maille Shirt

[dhawktx]

I've been dabbling around over at Shapeways.com and purchased several readymade items that 'work' at dolls scale.

From Whystler's shop:
http://www.shapeways.com/model/147300/led_candelabra.html?gid=fg76807
http://www.shapeways.com/model/88765/3_tealight_lanterns.html?gid=fg76807
http://www.shapeways.com/model/25929/petal_box.html?gid=fg76807
http://www.shapeways.com/model/18789/small_sky_castle.html?gid=fg76807

Then I found a designer who was experimenting with micro chain maille and asked him if he was willing to collaborate on a doll scale project. He was quite interested and I just got my first sample of 1:5 scale maille, 3D printed in nylon (marketed by Shapeways as White Strong and Flexible). Below is my Fairyland ChicLine Rou showing it off (see first photo below). Next I have learn how best to finish it to a steel look, AND cut and join rings. But it sure beats knitting all that by hand with regular loops.

From stop4stuff's shop:
http://www.shapeways.com/model/298816/0_7mm_360_121_20.html?gid=fg76807
http://www.shapeways.com/model/297546/euro_4_in_1___484_rings.html?gid=fg76807
The designer has added SCALES for Scale maille! Squee!
http://www.shapeways.com/model/312998/336_scales_on_runner.html?gid=fg76807
Aaaand Japanese 6 in 1
http://www.shapeways.com/model/314354/japanese_6_in_1__0_7mm___1mm_wire_rings.html?gid=fg76807

[dhawktx]

1-5 scale doll w by stop4stuff chain maille by dhawktx1, on Flickr


Bitty Bitsu with by stop4stuff chain maille by dhawktx1, on Flickr

Next step:

Chain maille sample first washed thoroughly to remove any grease, then soaked in strong Rit Black overnight...What deposited on the nylon looks AMAZINGLY like rust. OMG! If I wanted to leave it as is, but protect the doll from possible dye stains, I'd coat it with matte acrylic medium. to keep the links from fusing it would require some vinyl gloves, thinning the medium a bit, then dipping and tossing the maille around in front of a fan, keeping it moving. This would be repeated till I was sure it was coated thoroughly.

Also, it lets you see the rough texture of the WSF. Other materials are smoother, but the higher the detail/smoothness, the more brittle the plastic is, for the most part.

Next step will be adding steel colored acrylic. Can't wait to see what it does!

[dhawktx]

I'm using Golden Paint's Fluid Acrylic in Fine Silver, straight from the bottle with a sacrificial bristle fan brush - the dabbing and scrubbing to get the paint applied is going to destroy it!



And - a closeup



Several coats will be required to completely cover the base rust color, and the rough texture of the WSF will keep it from being 'shiny smooth'. A new process where they 'polish' the WSF may help get smoother maille, but I'm not sure the maille can handle it.

[zirconmermaid]

I can't wait until the whole shirt is done!

[Greyhaunt]

That is looking really fantastic! Excellent work on the painting - I'm utterly and totally impressed!

[landwhale]

Looks great!

[dhawktx]

Thanks all! It's taking a LOT longer to cover all the 'rust' than I thought it would. I've avoided a 'dipping' because it would take a lot of work to make sure rings didn't fuse with paint...now every time I think I'm done, the next day I rattle it around to loosen the tiny spots where it DID fuse, and all sorts of unpainted spots show up.

Argh!

On the good side, the Fluid Acrylics are only slightly thicker than airbrush paint, so they aren't leaving too much bulk considering the layers I've added.

I'm using this pattern to make the first shirt (Hauberk) to fit my 25.3cm IOS Jack (the taller fellow here).
http://www.bladeturner.com/pattern/hauberk/hauberk.html




Cost so far is a little more than $25 in maille, a $1 package of Rit dye, an $8 bottle of paint and the brush. Considering how much it would cost to pay someone to MAKE mini-maille out of rings, that's pretty cheap. Additionally, I never have to worry about this scratching my doll.

[dhawktx]

Fascinating Discovery #1: the Perfect Thread Sealer by BeadBuddy.net is also a perfect welding iron for nylon mini chain maille links.

http://beadbuddy.net/images/Thread%20Sealer%20Large.jpg
http://www.amazon.com/s/ref=bl_sr_arts-crafts?_encoding=UTF8&node=2617941011&field-brandtextbin=Bead%20Buddy


Not so Fascinating Discovery #2: Linking mini chain maille too late at night means you have to undo the whole demmed thing and do it over again, only in the right places this time.

[dhawktx]

Three smaller bits are now one bigger bit, and the micro 'welder' works wonderfully.

A short application of the heated tip is sufficient to melt the open edge. Pressing the edges together results in a near instant bond and there is just enough time to tap down any spiky bit before it cools too much.


tip of thread fuser by dhawktx1, on Flickr


sheet with pen and fuser for scale by dhawktx1, on Flickr

After working about halfway through the project, I've developed my technique to the point that I can weld the cut loop back together almost invisibly. Note that, in the sample below the bottom left has a completely hand welded chunk approx five rows tall by 20 rows wide.


sheet closeup 1 by dhawktx1, on Flickr

[dhawktx]

Here's some piccies of the WIP hauberk being modeled by it's intended recipient, Jack (yes, my work areas are a mess):


Jack and hauberk 1 by dhawktx1, on Flickr


Jack and hauberk 2 by dhawktx1, on Flickr


Jack and hauberk 3 by dhawktx1, on Flickr


Jack and hauberk 4 by dhawktx1, on Flickr